2008 international ansys conference · • growth segment of the packaging graphics portfolio •...

© 2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

2008 International ANSYS Conference

Role of Simulation in Product Development of Cyrel® Fast Thermally processed flexographic plates

Wil Shamlin - ConsultantDuPont Engineering Research & TechnologyParticle Technologies - SEPARATIONS


Imaging Technologies

The world’s first thermally processed flexographic printing plate system!

Introducing...


• Thermal development system for producing flexographic printing plates

• Photopolymer plate• Thermal developer• Developer Roll (nonwoven

material)• Exposed through a mask, processed

to remove unexposed material• Replaces solvent development and

drying

PET Coversheet

Digital ablation layerPrint surface layer

Photopolymer

PET Support

The plate

Graphics that sell products

What is Cyrel®FAST ?


• Imaged plate mounted on drum• Drum and developer roll heated• Unexposed photopolymer softens

with heat to allow flow• Molten polymer absorbed by

non-woven fabric– 8-12 revolutions/contacts with

fabric for 15 to 30 mils (.375 to .75mm) of relief

• No solvent involved! No Drying time!• Plate from box to press in 1 hour!

System Description


Problem Definition

• Vapors evolve from plate in heated nip

• Most vapors condense rapidly to form very small droplets

• Remaining vapors can condense as exhaust gases cool

• Need an improved design that is:–Effective on liquid and vapors–Safe in customer’s hands–Serviceable–Fits inside machine


The Business Stake for Corporate Funding

• Growth segment of the Packaging Graphics portfolio

• It underscores DuPont’s technology and market leadership

• It offers customers access to plates faster (hence the name) without the use of solvents

• The value proposition combines improved productivity with reduced environmental footprint

• Reducing the emissions

–Makes the best system in the market even better –Unlocks the power of sustainability


Technical Program

• Objective

– Understand mass transfer of aerosol and VOC in and around hot roll and drum

– Reduce emissions of aerosol and VOC

– Two technical approaches to solve problem

• Cool/condense/capture/filter/adsorb residual VOC• Heat/evaporate/capture/oxidize/quench vent gases

• Evaluate and select preferred technology


Role of Simulation

• Apply bench scale test data to machine design

– Filter efficiency at test conditions and geometry– Cat ox conversion at test conditions and geometry

• Simulate new conditions and new geometry

– Filters– Catalytic oxidizer– Designed to fit into condensation box space

• 1D empirical correlations scale to new design • 3D simulation translate to new design accurately• Mechanistic modeling of geometry specific design• Confidence in development is improved


Preferred Technology

• Exercise of models reveals optimum solution• Particle tracking and porous media modeling

– Process Technologies• Brownian Diffusion Filter• Coalescing Filter• Scrubber• Catalytic Oxidizer (preferred technology)

– Simulation input and response• Flow/ temp /press/ concentration/ particle-size

distribution– Filter efficiency / pressure drop

• Flow/ temp / press / concentration / combustion air– Cat Ox conversion / pressure drop


Simulation of Shrouds and Baffles


Heating and Evaporation in Manifold

• Area of interest - manifold


Detailed Flow in Manifold


Temperature Distribution


Temperature Distribution in Machine


Workflow

• Multidisciplinary team

• Pro/E machine design• ICEM CFD advanced meshing in Workbench• CFX-Pre for CFD set up• Workbench Simulation for FEA set up• FE Modeler for Abaqus legacy models• CFX-Solve to CFD/FEA coupling and solution• CFX-Post for visualization of fluid/structure analysis


Cyrel® Fast Program

Mark HacklerMark ArmstrongDoug JurusikBill McMillenCarmo PereiraJim GrantTom SimpsonRick NopperJim Henderson

Acknowledgement


Pro/E Geometry Acquisition


ICEM CFD Advanced Meshing

•Complex geometry


Manifold & Condensate Box - CFX-Pre

Pro/E Solid

Geometry from

Equipment Mfg


Workbench Simulation


FE Modeler

• Cyrel® Fast thermal analysis initiated in Abaqus

– Element imported into WB simulation crucial– Legacy model integration facilitated with skin

feature– Thermal analysis boundary conditions set with

CFX – Wider selection of multiphysics models in

ANSYS


Flow Distribution in Machine


Path Forward

• Thermal / Structural analysis is Abaqus based– Expand use of FE Modeler in WB environment– Integrate multiphysics coupled elements– Utilize ANSYS equivalent elements

• Accelerate use of simulation in product development– Understand its role– Drive cycle time to a minimum

2008 international ansys conference · • growth segment of the packaging graphics portfolio •...

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